Pu composite and method of fabricating the same

ABSTRACT

A PU composite and a method of fabricating the same are provided. The fabrication method includes: (a) providing a release paper; (b) coating a fabric layer on the release paper, the fabric layer containing a PU resin, an abrasion resistant, and a colorant; (c) drying the fabric layer; (d) coating a first laminated layer on the fabric layer; (e) drying the first laminated layer; (f) laminating a wet PU foam layer on the first laminated layer; (g) releasing the release paper to form a semi-product; (h) providing a plastic layer, which is of a thermoplastic; (i) coating a second laminated layer on the plastic layer; (j) drying the second laminated layer; and (k) laminating the semi-product of Step (g) on the second laminated layer, so as to form a PU composite. Compared with conventional PU composites, the PU composite of the present invention has better UV resistance, solvent resistance, and abrasion resistance.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a PU composite and a method offabricating the same. More particularly, the present invention relatesto a PU composite comprising an abrasion resistant and a colorant and amethod of fabricating the same.

2. Description of the Related Art

Referring to FIG. 1, a schematic cross-sectional view of a conventionalPU composite disclosed in ROC (TW) Patent application No. 095139709 (TWPublication No. TW200706361) is shown. A conventional PU composite 1includes a plastic layer 11, a second laminated layer 12, a wet PU foamlayer 13, a first laminated layer 14, and a fabric layer 15. Thematerial of the plastic layer 11 is thermoplastic. The second laminatedlayer 12 is located on the plastic layer 11. The wet PU foam layer 13 islocated on the second laminated layer 12. The first laminated layer 14is located on the wet PU foam layer 13. The fabric layer 15 is locatedon the first laminated layer 14, and the material of the fabric layer 15is a PU resin that has a texture on the surface thereof.

In application, the conventional PU composite 1 is attached to asubstrate, which is generally a housing of an electronic device (forexample, notebook computer, PDA, mobile phone, or LCD). After injectionmolding and then heat pressing, the PU composite 1 is attached to thehousing by the plastic layer 11. In such a manner, the texture of thefabric layer 15 and the entire artificial leather of the conventional PUcomposite 1 can improve the quality of the feeling of the electronicdevice.

The conventional PU composite 1 is fabricated by a common PU leathermanufacturing method, and thus, the test results of the propertiesthereof are as follows: 1. the solvent resistance test (tested accordingto AATCC GREY method) is at Grade 2; 2. the surface abrasion test(tested according to ASTM D3884 CS-10 1 Kg method) is 300 times; 3. theUV resistance test (tested according to ASTM G53 method, at theconditions: UVA wavelength of 340 nm, at 60° C.×4 hr→50° C.×4 hr→repeatfor 96 hr) is at Grade 2. Therefore, it can be known that theconventional PU composite 1 has the disadvantages of poor UV resistance,poor solvent resistance, and poor abrasion resistance, thus reducing thepracticality significantly.

Therefore, it is necessary to provide a PU composite and a method offabricating the same to solve the above problems.

SUMMARY OF THE INVENTION

The present invention provides a method of fabricating a PU composite,which includes: (a) providing a release paper; (b) coating a fabriclayer on the release paper, the fabric layer comprising a PU resin, anabrasion resistant, and a colorant; (c) drying the fabric layer; (d)coating a first laminated layer on the fabric layer; (e) drying thefirst laminated layer; (f) laminating a wet PU foam layer on the firstlaminated layer; (g) releasing the release paper, so as to form asemi-product; (h) providing a plastic layer, which is made of athermoplastic; (i) coating a second laminated layer on the plasticlayer; (j) drying the second laminated layer; and (k) laminating thesemi-product of Step (g) on the second laminated layer, so as to form aPU composite. Compared with the conventional PU composite, the PUcomposite of the present invention has better UV resistance, solventresistance, and abrasion resistance.

The present invention further provides a PU composite, which includes aplastic layer, a second laminated layer, a wet PU foam layer, a firstlaminated layer, and a fabric layer. The material of the plastic layeris thermoplastic. The second laminated layer is located on the plasticlayer. The wet PU foam layer is located on the second laminated layer.The first laminated layer is located on the wet PU foam layer. Thefabric layer is located on the first laminated layer and comprises a PUresin, an abrasion resistant, and a colorant.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross-sectional view of a conventional PUcomposite; and

FIGS. 2-6 are schematic cross-sectional views of a method of fabricatingthe PU composite according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

As used in this specification, the term “PU composite” refers to acomposite composed of a plurality of layers, in which a layer comprisespolyurethane (PU) resin.

FIGS. 2-6 show the schematic cross-sectional views of a method offabricating the PU composite according to the present invention.Firstly, referring to FIG. 2, a release paper 20 is provided, which hasa surface 201. The surface 201 preferably has a texture. Next, a fabriclayer 25 is coated on the release paper 20. The fabric layer 25 has asurface 251, which contacts the surface 201 of the release paper 20. Theformulation of the fabric layer 25 comprises PU resin, abrasionresistant, and colorant. The fabric layer 25 preferably comprises atleast 5-50 wt % of PU resin, 0.05-5 wt % of abrasion resistant, 0.05-15wt % of colorant, 50-75 wt % of methyl-ethyl ketone (MEK), 5-15 wt % ofdimethylformamide (DMF), and 1-10 wt % of toluene (TOL). The abrasionresistant preferably comprises silicone to improve the abrasionresistance of the PU composite. The colorant improves the UV resistanceand the solvent resistance of the PU composite, and preferably, theparticle size of the colorant is less than 10 μm, preferably less than 5μm.

Next, referring to FIG. 3, after drying the fabric layer 25, a firstlaminated layer 24 is coated on the fabric layer 25. The first laminatedlayer 24 is a paste, and the material thereof can be pressure-sensitiveadhesive, moisture-curable resin, one-component resin, or two-componentresin, and so on. Next, after drying the first laminated layer 24, a wetPU foam layer 23 is laminated on the first laminated layer 24. Therelease paper 20, the fabric layer 25, the first laminated layer 24, andthe wet PU foam layer 23 are then preferably placed for ripening andshaping.

Next, referring to FIG. 4, the release paper 20 is released, so as toform a semi-product 2. After releasing, the surface 251 of the fabriclayer 25 has a texture corresponding to the texture of the surface 201of the release paper 20. The semi-product 2 is preferably furthersubjected to a surface treatment.

Next, referring to FIG. 5, a plastic layer 21 is provided. The materialof the plastic layer 21 is thermoplastic, which is selected from thegroup consisting of polycarbonate (PC), acrylonitrile-butadiene-styrenecopolymer (ABS), polyurethane (PU), acrylic, and mixtures thereof. Then,a second laminated layer 22 is coated on the plastic layer 21. Thesecond laminated layer 22 is a paste, and the material thereof can bepressure-sensitive adhesive, moisture-curable resin, one-componentresin, or two-component resin, and so on. Next, the second laminatedlayer 22 is dried.

Finally, referring to FIG. 6, the semi-product 2 is laminated on thesecond laminated layer 22, and thus, the wet PU foam layer 23 of thesemi-product 2 is laminated on the second laminated layer 22, so as toform a PU composite 3. The PU composite 3 is preferably placed forripening and shaping.

Then, referring to FIG. 6, a schematic view of the PU composite of thepresent invention is shown. The PU composite 3 includes a plastic layer21, a second laminated layer 22, a wet PU foam layer 23, a firstlaminated layer 24, and a fabric layer 25.

The material of the plastic layer 21 is thermoplastic, which is selectedfrom the group consisting of PC, ABS, PU, acrylic, and mixtures thereof.

The second laminated layer 22 is located on the plastic layer 21. Thesecond laminated layer 22 is a paste, and the material thereof can bepressure-sensitive adhesive, moisture-curable resin, one-componentresin, or two-component resin, and so on.

The wet PU foam layer 23 is located on the second laminated layer 22.The first laminated layer 24 is located on the wet PU foam layer 23. Thefirst laminated layer 24 is a paste, and the material thereof can bepressure-sensitive adhesive, moisture-curable resin, one-componentresin, or two-component resin, and so on.

The fabric layer 25 is located on the first laminated layer 24 andcomprises PU resin, abrasion resistant, and colorant. The fabric layer25 has a surface 251, and preferably, the surface 251 has a texture. Thefabric layer 25 preferably comprises at least 25-99.80 wt % of PU resin,0.1-25 wt % of abrasion resistant, and 0.1-50 wt % of colorant. Theabrasion resistant preferably comprises silicone to improve the abrasionresistance of the PU composite 3. The colorant can improve the UVresistance and the solvent resistance of the PU composite 3, andpreferably, the particle size of the colorant is less than 10 μm,preferably less than 5 μm.

The thickness of the plastic layer 21 is preferably 0.10-0.20 mm, thethickness of the second laminated layer 22 is 0.01-0.15 mm, thethickness of the wet PU foam layer 23 is 0.20-0.45 mm, the thickness ofthe first laminated layer 24 is 0.01-0.15 mm, and the thickness of thefabric layer 25 is 0.01-0.05 mm. The total thickness of the PU composite3 is 0.38-0.90 mm.

The present invention will be further illustrated with reference to thefollowing embodiments, but the present invention is not limited to thedisclosure of the embodiments.

Embodiment 1

Firstly, a release paper is provided which has a texture on a surface.Next, a fabric layer is coated on the surface having the texture of therelease paper. The fabric layer comprises: 20 wt % of PU resin, 0.5 wt %of abrasion resistant (the abrasion resistant comprises silicone), 0.5wt % of colorant (the particle size of the colorant is less than 10 μm),64 wt % of MEK, 10 wt % of DMF, and 5 wt % of TOL.

Next, after being dried in an oven, a first laminated layer is coated onthe fabric layer. The first laminated layer is of one-component resin.After being dried in an oven again, a wet PU foam layer is laminated onthe first laminated layer, and then placed for ripening and shaping forabout 24 hr.

Next, the release paper is released to form a semi-product. Then, thesemi-product is subjected to a surface treatment.

Next, a plastic layer is provided. The material of the plastic layer isPC. A second laminated layer is coated on the plastic layer, and thematerial of the second laminated layer is the same as that of the firstlaminated layer. The second laminated layer is then dried in an oven.

Finally, the wet PU foam layer of the semi-product is laminated on thesecond laminated layer to form a PU composite. Then, the PU composite isplaced for ripening and shaping for about 24 hr.

The PU composite prepared in this embodiment includes a plastic layer, asecond laminated layer, a wet PU foam layer, a first laminated layer,and a fabric layer in sequence. The material of the plastic layer is PC.The material of the second laminated layer is one-component resin. Thematerial of the wet PU foam layer is PU resin. The material of the firstlaminated layer is the same as that of the second laminated layer. Thefabric layer comprises 95.2 wt % of PU resin, 2.4 wt % of abrasionresistant, and 2.4 wt % of colorant. Because MEK, DMF and TOL in thefabric layer are volatilized during drying, only the PU resin, theabrasion resistant, and the colorant are left in the fabric layer of theresultant PU composite, and the weight percentages are changed as well.

The test results of the PU composite prepared in this embodiment are asfollows: 1. the solvent resistance test (tested according to AATCC GREYmethod) is at Grade 5; 2. the surface abrasion test (tested according toASTM D3884 CS-10 1 Kg method) is up to 4000 times; 3. the UV resistancetest (tested according to ASTM G53 method, using these conditions: UVAwavelength of 340 nm, at 60° C.×4 hr→50° C.×4 hr→repeat for 96 hr) is atGrade 5.

Embodiment 2

The fabrication method of this embodiment is the same as that ofEmbodiment 1, except for the formulation of the fabric layer. The fabriclayer of this example comprises: 20 wt % of PU resin, 0.5 wt % ofabrasion resistant (the abrasion resistant comprises silicone), 0.5 wt %of colorant (a conmnon colorant, having a particle size greater than 10(m), 64 wt % of MEK, 10 wt % of DMF, and 5 wt % of TOL.

In the PU composite prepared in this embodiment, the fabric layercomprises 95.2 wt % of PU resin, 2.4 wt % of abrasion resistant, and 2.4wt % of colorant.

The test methods of this embodiment are the same as those of Example 1,and the test results are as follows: 1. the solvent resistance test isat Grade 2; 2. the surface abrasion test is up to 4000 times; 3. the UVresistance test is at Grade 2.

Embodiment 3

The fabrication method of this embodiment is the same as that ofEmbodiment 1, except for the formulation of the fabric layer. The fabriclayer of this embodiment comprises: 20 wt % of PU resin, 0.5 wt % ofabrasion resistant (the particle size of the abrasion resistant is lessthan 10 μm), 64.5 wt % of MEK, 10 wt % of DMF, and 5 wt % of TOL.

In the PU composite prepared in this embodiment, the fabric layercomprises 97.6 wt % of PU resin and 2.4 wt % of colorant.

The test methods of this embodiment are the same as those of Embodiment1, and the test results are as follows: 1. the solvent resistance testis at Grade 5; 2. the surface abrasion test is 300 times; 3. the UVresistance test is at Grade 5.

The test results of the above three embodiments are shown in thefollowing table.

Embodiment 1 Embodiment 2 Embodiment 3 Solvent resistance test Grade 5Grade 2 Grade 5 (tested according to AATCC GREY method) Surface abrasiontest Up to 4000 Up to 4000 300 times (tested according to times timesASTM D3884 CS-10 1 Kg method) UV resistance test Grade 5 Grade 2 Grade 5(tested according to ASTM G53 method, using these conditions: UVAwavelength of 340 nm, at 60° C. × 4 hr→50° C. × 4 hr→ repeat for 96 hr)

While several embodiments of the present invention have been illustratedand described, various modifications and improvements can be made bythose skilled in the art. The embodiments of the present invention aretherefore described in an illustrative but not restrictive sense. It isintended that the present invention should not be limited to theparticular forms as illustrated, and that all modifications whichmaintain the spirit and scope of the present invention are within thescope defined in the appended claims.

1. A method of fabricating a PU composite, comprising: (a) providing arelease paper; (b) coating a fabric layer on the release paper, thefabric layer comprising PU resin, abrasion resistant, and colorant; (c)drying the fabric layer; (d) coating a first laminated layer on thefabric layer; (e) drying the first laminated layer; (f) laminating a wetPU foam layer on the first laminated layer; (g) releasing the releasepaper, so as to form a semi-product; (h) providing a plastic layer,wherein the material of the plastic layer is thermoplastic; (i) coatinga second laminated layer on the plastic layer; (j) drying the secondlaminated layer; and (k) laminating the semi-product in Step (g) on thesecond laminated layer, so as to form a PU composite.
 2. The method asclaimed in claim 1, wherein in Step (a), a surface of the release paperhas a texture.
 3. The method as claimed in claim 1, wherein in Step (b),the fabric layer comprises 5-50 wt % of PU resin, 0.05-5 wt % ofabrasion resistant, and 0.05-15 wt % of colorant.
 4. The method asclaimed in claim 1, wherein in Step (b), the abrasion resistantcomprises silicone.
 5. The method as claimed in claim 1, wherein in Step(b), the particle size of the colorant is less than 10 μm.
 6. The methodas claimed in claim 1, further comprising a step of surface treatmentafter Step (g).
 7. The method as claimed in claim 1, wherein in Step(h), the material of the plastic layer is selected from the groupconsisting of polycarbonate (PC), acrylonitrile-butadiene-styrenecopolymer (ABS), polyurethane (PU), acrylic, and mixtures thereof.
 8. APU composite, comprising: a plastic layer, the material of the plasticlayer being thermoplastic; a second laminated layer, located on theplastic layer; a wet PU foam layer, located on the second laminatedlayer; a first laminated layer, located on the wet PU foam layer; and afabric layer, located on the first laminated layer, and comprising PUresin, abrasion resistant, and colorant.
 9. The PU composite as claimedin claim 8, wherein the material of the plastic layer is selected fromthe group consisting of PC, ABS, PU, acrylic, and mixtures thereof. 10.The PU composite as claimed in claim 8, wherein the materials of thefirst laminated layer and the second laminated layer are selected fromthe group consisting of pressure-sensitive adhesive, moisture-curableresin, one-component resin, and two-component resin.
 11. The PUcomposite as claimed in claim 8, wherein a surface of the fabric layerhas a texture.
 12. The PU composite as claimed in claim 8, wherein thefabric layer comprises 25-99.80 wt % of PU resin, 0.1-25 wt % ofabrasion resistant, and 0.1-50 wt % of colorant.
 13. The PU composite asclaimed in claim 8, wherein the abrasion resistant of the fabric layercomprises silicone.
 14. The PU composite as claimed in claim 8, whereinthe particle size of the colorant of the fabric layer is less than 10μm.
 15. The PU composite as claimed in claim 8, wherein the thickness ofthe plastic layer is 0.10-0.20 mm, the thickness of the second laminatedlayer is 0.01-0.15 mm, the thickness of the wet PU foam layer is0.20-0.45 mm, the thickness of the first laminated layer is 0.01-0.15mm, the thickness of the fabric layer is 0.01-0.05 mm, and the totalthickness of the PU composite is 0.38-0.90 mm.
 16. The PU composite asclaimed in claim 8, wherein the solvent resistance test of the surfaceof the fabric layer is tested and shown to be above Grade 4 according toAATCC GREY method.
 17. The PU composite as claimed in claim 8, whereinthe surface abrasion test of the surface of the fabric layer is testedand shown to be up to 4000 times according to ASTM D3884 CS-10 1 Kgmethod.
 18. The PU composite as claimed in claim 8, wherein the UVresistance test of the surface of the fabric layer is tested and shownto be above Grade 3 according to ASTM G53 method.